How to Increase Your Golf Cart Speed - Gear Upgrade Install

Today we're going to look at how I upgraded the gears in an EZGO Golf Cart from a 12:44 ratio to a 6:1 on a dana rear end. I've already upgraded the motor, controller, and voltage.
This was by far the most comprehensive install I've ever done. Before you start bashing me, I'm not a mechanic and this isn't what I do full time. Feel free to leave constructive feedback for others that might help with the install.
This isn't a terribly hard thing to do, but I've never seen it done before and had to work through a lot of the process myself. You'll see some things that I tried that didn't work and you'll see what ultimately did work. In the end, I'm going to show you exactly what the gear upgrade did for the speed of the golf cart.
I put some links below to the parts I needed to complete this upgrade - it really helps me out if you order from those links.
These EZGO Golf Cart high speed Gears are for 1988'-UP Electric & 2 Cycle Motors and the 6:1 Ratio is the FASTEST gear set you can buy. These gears will lower the amount of torque you used to have simply by the ratio. A lot of the gears come from Apache Gears in Arizona, but I ordered these through Amazon and I'll put a link down below. The gears come in 6:1, 8:1 and 15:1 if you decide you want more torque. The bulk of the driving we do is on flat surfaces, so torque and hills aren't a concern.
6:1 Gears for EZGO - amzn.to/3eZnh0e
RTV Gasket Maker - amzn.to/2C5DMcw
Synthetic Gear Oil - amzn.to/2ZDrQXN
Snap Ring Pliers - amzn.to/3itoz5R
Dead Blow Hammer - amzn.to/3gFukfK
Bearing Race and Seal Bushing Driver Install Set - amzn.to/3gEkY48
Gear Press - amzn.to/31H45k5
Freeze Plugs - amzn.to/3gCSqbb
The Camera gear I own and use for videos (I use multiple cams for different angles):
Perfect Camera for walking around - DJI Action 2: amzn.to/457p6C6
Gimbals are everything and make shooting easier - DJI Pocket 2: amzn.to/47mQbD2
First RF series camera - great for 4k - Canon R6: amzn.to/4418R8y
Beast mode cam for action shots and video - Canon R3: amzn.to/3rPArIv
Wide ranging lens great for video zoom - Canon 15-35mm lens: amzn.to/441AU7U
Cost effective fixed RF lens - Canon 35mm lens: amzn.to/3Or1Acz
Very wide shots for your RF cam - Canon 16mm lens: amzn.to/3qkzLKR
A must have tripod for your camera gear - Joby Tripod: amzn.to/3KuuZS5

[@AndiWofford]

If you want to do this yourself, the gears are here: *6:1 Gears for EZGO* - amzn.to/3eZnh0e and the *freeze plugs* you need are here - amzn.to/3gCSqbb

[@rogerhebert8966]

Part number for the bearings?

[@nickgriffith5302]

l in

[@nicholascbryant]

I felt my "man card" spontaneously combust while watching you work. I think it was the sparkly nails that was the nail in the coffin🤣 Great Job!

[@TheNicko773]

Excellent work. This job is for the mechanically inclined, and you showed that you have what it takes. Thanks for sharing.

[@AndiWofford]

Thank you so much! I had fun doing it!

[@brekmiley1472]

Incredibly detailed and instructional. Also the video quality was top notch. I came here looking for golf cart rear gear change specifically so I could get a baseline idea before doing mine this weekend but I have now subscribed to the channel. Not sure what other videos you have but looking forward to checking them out. Keep up the awesome work!

[@AndiWofford]

Thank you so much! So happy you were able to get something out of the video. Lots of comments on here from experts, so even more to learn 😉

[@aaronburnette4585]

Thanks brother. This is exactly the video I needed to see! Great install, keep up the good word man!

[@bdub3871]

Great video. I like how he takes the time to explain in details each little step. Easier to understand for those who are mechanically challenged.

[@macknumber9]

He?

[@payscue189]

​@@macknumber9yep.

[@danburch9989]

That "drain plug" really isn't a drain plug. It's a fill hole. You can drain the differential pan by syphoning most of the lubricant with a $20 vacuum pump from HF or any auto parts store. Also, nuts and bolts are torqued to foot pounts or inch pounds. Liquids are measured in PSI (pounds per squre inch). I don't think the nuts and bolts really cared what term you used😉. In any case, the end result of your project was outstanding!

[@kennethmarsh4897]

Thank you for this video! This has given me much insight on doing my gear upgrade project.

[@AndiWofford]

Hope it helps! Good luck with yours!

[@dutchleussink156]

Well done! Learned a bunch Thank You.

[@AndiWofford]

Thank you!

[@SunriseDentalLab]

Good job! I absolutely know how awkward it is to hold that motor up when working from the bottom. Taking the body off seems excessive but I can tell you it makes everything so much easier.

[@AndiWofford]

Thank you for the feedback! I'm sure that if I did this all the time, I would certainly be taking the body off. Too much trouble working from underneath

[@unclerob617]

Just a friendly comment from an old retired Dana employee. I find the older I get, the more pragmatic I become. Since you mentioned you have replaced the motor and that you've installed a lift kit.... this would lead me to believe you are absolutely capable and familiar with removing the complete rear diff from the cart. I would have suggested taking it to a differential shop and having them swap the gears for you. Any differential shop or driveline shop could do the swap for you blindfolded and probably for a case of beer if you ask the right person. Dana is a household name to them. Considering the price of the tools you bought and ruined in this process you would probably come out ahead in the end? And a lot of times if you let them supply the parts for you it allows them to make a bit of profit on that side as well (don't take a steak to a restaurant and ask them to cook it for you). So now you have a boat anchor arbor press... and you busted your butt on the conversion. You have my respect for your fearless determination... there are only a very few like you. 👍And also BTW... awesome job on the video!!!

[@AndiWofford]

Thank you Uncle Rob. Totally understand where you're coming from and had I not been looking to film a project with me figuring it out and doing it myself, I certainly could've taken it somewhere. But believe it or not, I love the challenge and I had a blast getting this done and proving to myself I could do it. Yes, I destroyed a cheap press thingy, and it's probably because I didn't know how to use it. This whole channel is very much a "how I did it" and less about the "right way to do it". I do believe you have the right approach in the long run, but as long as others find it entertaining, I'll keep tackling new stuff.

[@GAQ0709]

Great job.😊

[@trobolt1]

Another awesome video! I have been looking at disk front brakes. Have you ever considered a brake upgrade? The TXT doesn't stop that well with larger tires and a full complement of people....especially in hilly terrain. Thanks again !

[@AndiWofford]

Thank you! It's funny you should mention brakes 😂. I just ordered a pair of rear disc brakes today. They should be in next week. After an install, the video should be out in a couple of weeks. For right now we'll just do the rear, but if I feel like it I might do some front disc as well 🤷🏼‍♀️. Time will tell. Thanks for checking out the vids 😁

[@hmtrimworks7148]

You got me thinking I’m going to be wanting to do that! Although I think I will remove the rear and do it on the bench

[@AndiWofford]

Might be easier to remove the whole rear end!

[@turbulence8638]

Awesome job.

[@AndiWofford]

Thanks!

[@dayronreyes3665]

Thank you the video, really help, where did you get the bearings for the differential, what size were them?

[@hillbillybassfisherman8181]

awesome i am going to take a golf cart project on but im going to use club cart cause of the better frame

[@Lakanuki]

Excellent video. Very detailed with good sound and video technique. I need to do a gear change on a yamaha gas cart. Any idea what would be different? Wanna help?

[@AndiWofford]

That sounds really interesting. I'm not sure on the gassers, I hear they're different. But if it had the same Dana rear it might not be terribly difficult. I figured it out by tearing into it, so I'm sure if it can be done, you can figure it out!

[@darrylstiner4245]

Thanks for the video! I installed 8:1 gears yesterday that brings my non-lifted cart to 32mph with the alltrax controller and d&d motor.

[@AndiWofford]

I'm really glad to hear that! That's really fast for 8:1 - sounds awesome!

[@mygt8a4re]

Hey Darryl, what size controller, what motor (torque/speed) and what size tires? Curious of your results before gearing. Thanks!

[@darrylstiner4245]

@@mygt8a4re with the stock 36v motor, tires, controller and chip it only did 18mph After the 48v conversion with alltrax xct48500 controller, 500amp solenoid, larger cables, 8:1 gears, 12" wheels, d&d motor 170-500-0001 it now goes 32 mph with a custom field curve. The next cart I build I'm definitely going with an a/c conversion

[@mygt8a4re]

@@darrylstiner4245 wow the gears made a big difference in speed for you then. I'm 48v, 400a controller (2ga wires & upgraded solenoid) stock gearing on 18" tires and I go 24mph. Would hate to lose the torque I have now but would love to hit 30mph. Thanks for the response

[@darrylstiner4245]

@@mygt8a4re Mine still has plenty of torque for here in florida "no hills" next time I'm going to go with the 6:1 gears. This cart project was pretty much trial and error since there doesnt seem to be a lot of info out there on cart upgrades. The change from stock gearing to 8:1 gave me an increase of 8mph

[@JustWinJets]

My EZGO has a 6:1 gear ratio installed. I am running a 600amp navitas controller, 48v Trojan batteries & an FSIP Torque motor. Would going to a 23” tall tire work with my setup or would it not be a good idea? Thanks

[@n3qdz]

I love the video awesome job. I wonder if removing the axel If it would have made the job easier.

[@AndiWofford]

I'm now a firm believer that if you were to remove the entire differential and motor, you would have a much easier time doing this from a workbench at normal height rather than crawling around on the ground underneath it. But either way works. Thanks for the compliment!

[@markemerick7031]

Hey Andi, My user's manual shows SAE 30 lightweight gear lube, which I can't find anywhere. I noticed that you used 75/140 gear lube. Where did you find that recommendation, because I'd like to use that too. I was also wondering if you used any sort of sealer on the black freeze plugs. Thanks, -Mark

[@AndiWofford]

I had read from someone in a forum that that's the gear oil they used, so I used it. I make no claims as to what's right, as the 30 lube you mentioned is what you need (but hard to find) - basically you need an oil that'll coat the lower gear and transfer it up into the rest of the gears in the Dino rear end. And lastly, I didn't use any sealer on the freeze plugs. Those things fit super tight in the rear end and you don't need anything around them.

[@scootersonlyrepair6773]

Gear oil is just less refined motor oil you can use 10w50

[@mikes1330]

FYI Torque is specified in Foot-Pounds or Inch-Pounds, not "PSI" (pounds per square inch)

[@AndiWofford]

I think you're the 5th person to mention that in the comments and that's really the only mistake that's been called out. I spent 30 hours filming and editing this video and if that's the only mistake I made, then I'm super lucky!

[@mrturner69]

good job!

[@AndiWofford]

Thank you!

[@rodneyhendrickson5094]

What Year is your EZ-GO? Is why the years are different on the part numbers Mine is a 1995 txt and all I need now is the freeze plug cap? And the bearings I have everything else I need I hope Thanks

[@AndiWofford]

Hi Rodney. Mine is a 2000, which should have the same Dana rear end as you 1995. My 6:1 gears also fit EZGO ELECTRIC: 1992'-2013' Series, PDS, DCS, TXT, ST, and Some Workhorse Models.

[@luxgadget777]

hello I finally had my Clubcar dealer upgraded my lithium cart to high speed gear. So much faster now but I notice a much much louder high pitch whining noise when I decelerate. Is this normal? Dealer says the noise will ease off with break in period. Please advice.

[@scottdelaney98]

Great video. Seems like this would have been a convenient time to add a drain plug to the diff cover.

[@AndiWofford]

My understanding was that people use the existing plug and suck all the fluid out. But the plug is also there so you don't overfill the differential.

[@scottdelaney98]

@@AndiWofford yes that's exactly right. But it's handy to add a drain plug at some appropriate place on the bottom of the cover to allow you to drain and refill the diff without the hassle of trying to pump out the oil from the top. Drain from the bottom, fill from the top. Again, great video. You didn't gloss over the hard parts. 👍

[@abesanchez9753]

Now that you've done electrical and gears, do you think it would be easier to just leave all electrical alone and just do the gears for speed increase? Or do you think stock motor with 36v would not be enough torque to get a significant speed increase?

[@AndiWofford]

I think that if you did the 6:1 gear with a stock motor, you would be replacing it shortly anyway because you'd burn it up. There's no way, even without hills, that a stock motor would last very long on that gear. I still think: 1) controller, 2) voltage/battery, 3) motor, 4) gears worked best for me.

[@macknumber9]

​@@AndiWofford what about stock everything with 8:1 gears?

[@karihines211]

how much torque did you loose? im trying to decide if i want to do 8 to 1 or the 6 to 1. do you think yours would still climb hills ok if needed?

[@AndiWofford]

It would still climb, but I would lean towards the 8:1 if you're climbing any kind of hills. I'm all flat here so it's not an issue for me.

[@travis1118]

Well done! How much would you estimate you have put into your cart total?

[@AndiWofford]

Thanks! Way more than it's worth 🤣. Between the new batteries, motor, controller, gear, lift kit, seats, tires, wheels, top, lights, and other miscellaneous accessories, probably $4k

[@travis1118]

@@AndiWofford I'm in the market for a golf cart. Never realized a 10 year old used cart still goes for $6k. For that I figure I'll just buy new. Evolution sells a lifted 6 seater with Lithium batteries for $11k. I'm leaning towards it. Know anything about Evolution carts?

[@AndiWofford]

I know someone that has one, brand new, and it's back in the shop (to be honest, I don't know why though - he just said it was in the shop for something). But six seats and lithium for 11k sounds really good!

[@williamhartman9]

When upgrading to a navitas 440 amp controller do you need to upgrade solenoid and battery cables ?

[@williamhartman9]

Thank you

[@AndiWofford]

"When upgrading to a high amperage controller, replacing your old 4-gauge battery cables is recommended - this upgrade will reduce resistance and allow better thermal management." Nothing on golf cart king about the solenoid.

[@parales03]

You are a bad asssssss!!!!!!!!!!!!!!!

[@AndiWofford]

Thank you!

[@mikepijuan7044]

How much did it increase your top end after installing the gears ?

[@AndiWofford]

That question is wholly dependant upon a number of factors, including tire size, controller amperage, motor, and voltage. I go over it at the 17:50 mark in the video, exactly what the changes are and how it affects the top end.

[@williamgardner3065]

Did you have any motor heating after replacing the gears?

[@AndiWofford]

None that I've noticed, honestly. I don't push it too hard though anyway

[@luxgadget777]

Great video. Nice job. Do you need this to make your golf cart "Street Legal". My club car dealer told me that this is needed to make it street legal for Orlando Florida. I am not sure I believe him.

[@AndiWofford]

I believe every municipality has their own regulations. I wanted to add seat belts and a grab bar in the back, but I'm not sure anyone is policing the safety equipment where I live.

[@rogerhebert8966]

What is the part number for the bearings behind the dust cover

[@AndiWofford]

I ordered it from eBay as a kit, came with plugs and all the bearings (axle bearings and motor shaft bearings that I didn't use too). Shipped very quickly: rover.ebay.com/rover/1/711-53200-19255-0/1?ff3=4&pub=5575460613&toolid=10001&campid=5338441563&customid=&mpre=https%3A%2F%2Fwww.ebay.com%2Fitm%2F254357816318

[@mygt8a4re]

Great vid! May I ask, if you had to do it all over again, would you have just bought a different motor, one that offers about 10% more torque and several mph from where you were? Iknow the learing experience is priceless but....Just curious, thank you for sharing this vid!

[@AndiWofford]

Hi Justin! I think I still would've done the gear upgrade. I mean, it was costly but worth it in the end. It wouldn't have taken me nearly as long if I wasn't filming it and if I actually had a video to go by 😂. Still, I bought a motor for torque and I probably would've bought one for speed instead. Looking at lithium batteries next to get a voltage boost and see if that affects speed. Learning was super fun though.

[@mygt8a4re]

@@AndiWofford thank you for the reply and the insight of tackling this job. The Lithium conversion WILL gain you more power and speed. The weight saving alone makes the cart feel more nimble. As I'm sure you know the less weight forcing the cart to the ground along with the added speed can lead to some "iffy" cornering. Keep up the great content!

[@markemerick7031]

What is the part number for the bearing race tool referenced at 18:55

[@AndiWofford]

Part No. W83020 Product Features: Quickly and easily installs wheel bearing races and seals without destruction to race or axle housing. Set includes six discs to fit common bearing sizes. Sizes: 1.565, 1.75, 1.965, 2.325, 2.47 & 2.555"

[@zappisitaliangarden1886]

Is this high speed gear upgrade apply to my lithium onward

[@corky5928]

Well, I don't have an EZGO nor an electric cart so you probably won't be doing much that's relevant to my Yamaha EFI PTV. That said, what a great video, I enjoyed your adventure.

[@AndiWofford]

But this is what I'm shooting for, entertainment as well as help for those that might need it! So the fact that you enjoyed the adventure is enough for me to be happy! Thank you so much!

[@jerrymickle8751]

You rock

[@AndiWofford]

Thank you Jerry!

[@flyinghigh5031]

Nice work ?What are your tires total diameter?

[@AndiWofford]

14inch vector wheels and 23" tires. Just know that 23" tires is an inch too big for a 6" lift because you can't turn the wheel all the way to the left.

[@flyinghigh5031]

@@AndiWofford copy thanks!

[@MrHvacDUDE]

Very informative. I was debating doing mine. This video will save me half a day from trying to do it with no instructions 😂

[@AndiWofford]

Happy to help!

[@jerryhitt9991]

What size wheels & tires are you using.

[@AndiWofford]

23" tires

[@fatheadfpv5732]

Is the spider gear unit itself servicable? I need to replace my spider gears

[@AndiWofford]

I don't know about serviceable, but it's certainly replaceable. You can get to it by taking the plate off on the bottom of the differential housing.

[@fatheadfpv5732]

@@AndiWofford Yeah, I've already pulled a diff. It's not the diff, it's the input shaft gear. Or bearing

[@AndiWofford]

I've pulled everything out of the rear end, including the input shafts and everything all the way to the top of the pumkin. In fact, I think I did all that in this video.@@fatheadfpv5732

[@fatheadfpv5732]

@@AndiWofford yes you did. Unfortunately,now so am i.

[@lucasjacobushattingh3061]

hi do you mabe have old ezygo golfcart suspension 1994 mabe

[@AndiWofford]

I'm sorry, I sure don't

[@lucasjacobushattingh3061]

@@AndiWofford spares here for colfcarts is so overpriced but thanx

[@markemerick7031]

Oops, I meant the bearing race and seal bushing driver at 11:20

[@kevinburgess5066]

Did I miss it? What was the total cost for the project, tools and all?

[@jmathis2aug]

69

[@ryanirvin9886]

Did you notice much acceleration lose with the speed gear?

[@AndiWofford]

Honestly, not much loss. More of a gain because of the high torque motor

[@ryanirvin9886]

@@AndiWofford My 14 Yamaha 48V has an A/C motor and has tons of torque but didn't want to affect it too much.

[@AndiWofford]

Might be a good upgrade. Might do 8:1 instead of 6:1 so you're not going all the way out of the gate. But 6:1 was great for me

[@scottyrobin2504]

I can’t find the link to the gear package you purchased, can you email or answer my comment so I can change mine?

[@AndiWofford]

Hey Scotty - the gears are herel: *6:1 Gears for EZGO* - _amzn.to/3eZnh0e_ and the *freeze plugs* you need are here - _amzn.to/3gCSqbb_

[@scottyrobin2504]

Andi, Thanks, got it! Just so I’m ordering the correct amount, I need Two freeze plugs, is that correct?

[@AndiWofford]

That's correct! Just the two plugs. If you need bearings, you'll want to get those as well. I accidentally drilled in to mine, but it didn't damage it.

[@scottyrobin2504]

Andi, Thank you again

[@AndiWofford]

No problem Scotty, let me know if you have any questions and good luck!

[@camj256]

Amazon has like a 8 dollar hand pump that does wonder for getting gear oil in and out of differentials. Universal pump I think they call it. Pretty good for not being a mechanic! It's probably foot pounds not psi. Torque ratings are in inch pounds, foot pounds, and newtons.

[@AndiWofford]

I did think about the foot pounds, but at 30 + hours of editing and voiceovers I decided not to go back in to fix it 😁. But you're absolutely right.

[@scottyrobin2504]

Andi Wofford I really like your upgrades, I too tricked out my daughters cart with 6” lift, under glow, large tires and rims, stereo, backup camera mad Jax rear seat w/ beer cooler, street legal led light kit, subwoofer , it is really bad A$$! Now I am going to replace gears possibly for slight increase in speed, I hope but I will save the 48v upgrade when my wallet recovers a little. V/R, Scotty

[@macknumber9]

​@How I Did It how do you know how much gear oil and the right kind to use? I saw others fill it through a fill area and just stop once it starts coming out that

[@camj256]

@@macknumber9 that's exactly how much goes in. fill till it comes out the fill plug.

[@AndiWofford]

Exactly right

[@jerryhitt9991]

How much lift is on your cart.

[@AndiWofford]

6" lift

[@DIYReid]

If the gear oil doesn't go above the plug, how were you going to drain it before taking the pan off?

[@AndiWofford]

I had planned to use a clear plastic hose to siphon the oil out if I was going to empty it. ut you raise a good point - it's not the easiest thing to do.

[@jdcook65]

Very imformative. However, it's foot pounds, not PSI when torqing bolts and nuts.

[@AndiWofford]

Thank you!

[@chadowens9215]

How much is 40 psi?

[@AndiWofford]

It was a mistake because I had psi on the brain. I meant to say 40 foot-pounds of torque.

[@hillbillybassfisherman8181]

i think this would be good to change on a 36v to give a cart more pulling power gear for hills i know it slows the cart but make it pull like a mule

[@AndiWofford]

It definitely would!

[@macknumber9]

This would take away pulling power and give you more top speed....if you want straight pulling power you want a higher gear ratio

[@cameroncook975]

Time to add some batteries and go up to 60-72V

[@AndiWofford]

I'm seriously thinking about lithium batteries. There's so many advantages

[@goldenlife9856]

@@AndiWofford if you were going Lithium batteries you should do a AC motor and controller or keep it in mind. I needed more speed and with 72 volt LiFePO4 batteries and a Navitas AC kit I'm over 45 mph

[@AndiWofford]

45!?! 😳 With a teenager about to start driving it I'm not sure I want to make it too much faster 😂.

[@goldenlife9856]

@@AndiWofford nice thing about the Navitas Controller, you can make it as fast or slow as you want and lock the settings. 😁

[@luthierlong]

I love this but I thought I would have an appearance via our video call. It's all good though. Also torque is in ft.lbs. but you are not a professional mechanic so who really cares.

[@AndiWofford]

For some reason I had PSI on the brain when I was doing the voiceover. But I did talk about you in the video (I think?), I just didn't have clear audio from our chat. And I told you the other reason 😉

[@luthierlong]

I love it anyway. You're such a badass

[@antizakkonic7789]

Beat me to it, PSI and pound/feet (foot pounds to most of us) are not interchangeable terms. In fact, if you can actually find a torque wrench calibrated in PSI I'd be interested to know just where... and why. ; )

[@nike12000haha]

40 ft lbs not psi

[@jmathis2aug]

Yeahhh protect that shaft!

[@kevinvoyer5053]

The boy issue? The same pathetic brakes!

[@AndiWofford]

Brake upgrade is next - I have them ready to go. No one is really using the cart this summer, so we're ok for now. But agree that a brake upgrade is a necessity.

[@hillbillybassfisherman8181]

did you make the video so you have pictures to put it back hahahhahahahaha

[@AndiWofford]

You might actually need that 😂